Method of processing green tobacco leaves into cut tobacco

ABSTRACT

In general, this invention belongs to the tobacco production and processing sector and more specifically it refers to the method of producing cut rag tobacco for cigarettes and other products from green tobacco leaves by the innovative integration of the GLT and Primary processes, with lower investment and operational production costs, while generating cut rag tobacco with high filling power while maintaining a flavor approximately equal to that of the original tobacco.

Method for Processing Green Leaf Tobacco into Cut Tobacco Technological Invention Sector

In general, this invention belongs to the tobacco production and processing sector and more specifically it refers to the method of producing cut rag tobacco for cigarettes and other products from green tobacco leaves by the innovative integration of the GLT and Primary processes, with lower investment and operational production costs, while generating cut rag tobacco with high filling power while maintaining a flavor approximately equal to that of the original tobacco.

State of the Art

The worldwide tobacco industry, excluding China which alone represents nearly 42% of global tobacco production and consumption, has undergone significant change during the last 30 years. Brazil as the second largest green leaf producing country and single largest tobacco leaf exporting nation, represents well the general tendency seen worldwide, excluding China. From 1990 thru 2004, Brazil increased total green leaf tobacco production from approximately 300 million kilograms to nearly 700 million kilograms, of which flue cured Virginia tobacco represented 85 percent of the total; an overall increase of 133% in a 15 year time span. Brazilian tobacco production growth occurred partly as a result of significant reductions during that time period in the USA, Zimbabwe, and Europe. During the latest 15-year period, 2005 till 2020, Brazilian production has decreased from 700 to 500 million kilograms of green leaf tobacco; now nearly 90 percent flue cured Virginia tobacco. Total decrease during that 15-year period in Brazil has been nearly 30%; the rest of world tobacco production decreased approximately 20%, excluding China which reduced domestic green leaf production slightly, but also increased leaf tobacco imports to maintain domestic cigarette production relatively stable.

With projected worldwide conventional cigarette consumption continuing its decades long term tendency of annual consumption decrease of 2-3 percent, it is probable that the entire tobacco production global supply chain from farmers, to tobacco leaf processors (GLT) thru to cigarette manufacturers (including their Primaries and Secondaries); will continue their current trend of industry wide consolidation and overall reduction of conventional cigarette production and overall tobacco consumption. Successful companies to survive in this environment will have to either differentiate their products from the competition (which is difficult in a commodity type market such as tobacco); or more probably exert all efforts to be a low cost producer in their respective niche of the tobacco market.

In view of this overall worldwide situation, the invention herein described, contributes to the ability of the tobacco industry to reduce capital employed in tobacco production and industrial processes, reduce overall operating costs of cigarette production, maintain cigarette production quality standards at internationally acceptable standards, and contribute to the Sustainable Development Goals (SDG 9 “Industrial innovation and infrastructure” and SDG 12 “Responsible consumption and production”) as determined by the United Nations.

Therefore, some conventional terms to define tobacco processing and cigarette manufacturing are important to describe:

-   -   GLT (Green Leaf Threshing): factory in which green tobacco         leaves, delivered by farmers, are threshed, dried, pressed, and         packaged.     -   Primary: part of a cigarette factory that deals with blending,         conditioning, cutting, drying, and flavoring of tobacco before         making cigarettes; also called the prefabrication area.     -   Secondary: factory where the cigarettes are made.     -   Green tobacco: tobacco dried only in the farmer barn for curing         with hot air circulation, “not fermented” and not industrial         re-dried.     -   Cut tobacco: tobacco that has been cut into fine strips for use         in cigarettes. Also called cut rag.

During the pre-industrial phase, farmers:

-   -   Plant the tobacco seeds;     -   Grow the tobacco plants;     -   Harvest the tobacco leaves;     -   Dry/curing (not ferment) the tobacco leaves in barns;     -   Classify the tobacco leaves;     -   Pack in bales, or similar form of farmer packing, for subsequent         delivery to a GLT.

After packed in bales at the farmer location, the green tobacco in bundles or loose leaves are sent to a conventional GLT. Nearly all GLT processing worldwide currently of green tobacco is done similarly as in FIG. 1, or with slight variations.

Some patent documents illustrate the currently known process techniques:

-   -   Patent EP 2489283-“Method of processing tobacco leaves” which         reveals the standard used in the industry with 5 threshing         stages.     -   Patent WO 2019020370-“Method for producing cut tobacco” reveals         a process with the following steps; harvesting tobacco leaves;         fermenting the harvested tobacco leaves; threshing the fermented         tobacco leaves into threshed tobacco material; moistening the         threshed tobacco material; cutting the moistened tobacco         material into cut tobacco and drying the tobacco.     -   However, these processes still use conventional methods, except         for the need of fermented tobacco in WO 2019020370, and do not         promote a method of producing cut rag tobacco with market         acceptance that promotes overall cost reduction and reduction of         manufacturing steps.     -   Patent WO 2019020370-“Method for producing cut tobacco” requires         lamina cut width between 1.3 mm and 1.7 mm, which is larger than         the conventional cut width.     -   However the current Patent is applicable to any commercially         desired cut width, ranging from at or below 0.30 mm, including         up to and beyond 1.7 mm or greater.

In addition, a threshing plant (GLT) is a factory which receives the tobacco green leaves from the farmers and goes through the following steps:

-   -   Bales conditioning: the farmer bales, optionally, can be         conditioned and softened in a vacuum chamber.     -   Leaf grading: grades and blends are made up of the product from         the farms according to the customer specifications.     -   Leaf tipping: leaf tipping involves the cutting of the tip of         the leaf. These parts by-pass the threshing line, and thus         improve fragmentation in the GLT and sieve analysis in the         Primary.     -   Leaf conditioning: leaves are opened and softened by means of         steam in rotary ordering cylinders. Conditioning allows         threshing with minimum breakage. Product temperature is         controlled to ensure no loss in tobacco aroma.     -   Leaf threshing: threshing baskets are used with rotating teeth         moving past stationary baskets; the lamina is “ripped” from the         stem and the incoming leaf is thus changed into lamina and stem         product.     -   Leaf separation: classifiers are used to separate the product         received from the threshers into lamina and stem; more than one         combination of threshing heads and classifiers are used to         ensure optimum threshing with minimum waste.     -   Drying: after separated, lamina and stem are re-dried in         separate apron dryers.     -   Pressing: the re-dried lamina and stems are individually packed         into cardboard cases, for eventual shipment to a user's Primary.

FIG. 2 illustrates the description of a conventional Primary tobacco process where the lamina and stems from the GLT are received for eventual use in the individual blends to be processed to meet each customer's cigarette blend specification.

The conventional tobacco Primary process receives the GLT lamina strips and stems for the following process:

A) Lamina Processing

The lamina bales move forward on a blending line, passing thru a slicer before entering the DCCC (Direct Conditioning and Casing Cylinder) where conditioning and casing process takes place according to different blends. The moistened tobacco next enters the lamina bin silos for storage and bulking. Optionally it can also go through the steam tunnel for additional conditioning. Then, the lamina goes to the cutters, generating cut rag. Optionally, you can also go through the steam tunnel for further conditioning and/or expansion before the dryer. After the lamina has been cut, it goes to the dryer to attain the required moisture, desired expansion and tobacco taste profile expected for each blend being dried. Optionally it can go to the cooler and/or objectionable stem removal (normally 1% maximum of dried lamina input). At the Primary lamina line add-back station, the dried cut rag lamina is combined with the dried cut rag stems (see B—stem line) coming from the stem silos and other tobacco products, such as Recon, DIET, Scraps. After passing thru (optional) shaker(s), product passes thru a final cut rag blend flavor cylinder. After receiving the flavor, the combined product is conveyed to the Final Product Silos (optional) for homogenization plus assurance of required moisture as per blend or to the last step, which is to send final cut rag blend to Secondary for cigarette manufacture, or press/pack the product in cardboard cases (with optional Polyliner bag). Product can be used as needed wherever in the world, ideally within 6 to 12 months from final packing date.

B) Stem Processing

The stem cardboard cases are fed inside the tipper. It then goes to the washer for cleaning and the equipment for conditioning. Then the moistened stem tobacco enters the stem bin silos for storage and bulking, optional steam conditioning, and then sent to the cutters. After the stem has been cut, it goes to the dryer to attain the required moisture and desired expansion and then is stored in cut stem silos or other packaging to further add-back to the lamina cut rag.

New Attributes and Objectives of the Invention

FIG. 3 introduces a new tobacco processing method through partial integration of both the conventional GLT and conventional Primary into a both lower investment and operating cost process while at the same time producing a higher filling capacity cut tobacco and improved sieve analysis, along with high maintenance of the original tobacco flavor delivered from the farmer, when compared to conventional GLT as illustrated in FIG. 1 and Primary as illustrated in FIG. 2.

The following characteristics differ from the conventional process and can operate individually or jointly between one or all:

-   -   Leaf tipping increase equal to 30-35% in total lamina weight for         “Filler” and for “Leaf”, directly at the initial blending table.         This process is most efficient in countries in which the farmers         supply the tobacco in bundles or oriented loose leaves. Green         tobacco may be Virginia Flue Cured, Burley Air Cured, or any         other; independent of being non-fermented, fermented, or other.     -   Decrease of subsequent threshing and separator capacity by up to         at least 10 to 20% compared to the conventional 5-stage         threshing lines.     -   Elimination of the apron dryer for green lamina strips after         threshing.     -   Elimination of the dried lamina press after dryer.     -   Achieve significant final acceptable stem percentage removal in         the Primary instead of in the GLT. This requires an efficient         stem separator after the cut rag dryer.     -   Provides a significant increase in filling capacity of cut rag         produced and subsequent lower cut rag tobacco weight requirement         for each cigarette produced, when compared to conventional GLT         and Primary cut rag production.     -   Maintenance of high percentage of original tobacco leaf flavor         and at the same time maintaining high filling capacity.     -   Reduce overall investment and operating cost in the combined GLT         and Primary processes, and higher filling capacity final cut rag         compared to conventional process.     -   Improve cigarette maker runnability on medium and high speed         makers, with reduced cigarette rejection rates; both when         compared to conventional produced cut rag.     -   Cut rag tobacco produced using this method maintains tobacco         smoking characteristics similar to the results of conventionally         processed cut rag as per each blend.

DESCRIPTION OF THE ATTACHED DRAWINGS

In order for this invention to be fully understood and put into practice by any technician in this technological sector, it will be described in a clear, concise, and sufficient manner, based on the attached drawings listed below that illustrate and provide complementary information about it:

FIG. 1 represents the flowchart of the conventional tobacco processing and threshing plant (GLT);

FIG. 2 represents the flow chart of the conventional Primary tobacco process;

FIG. 3 represents the flowchart of the tobacco processing method with the partial integration of the conventional GLT with the conventional Primary processes.

DETAILED DESCRIPTION OF THE INVENTION

In general, the method illustrated with FIG. 3 is applicable to green tobacco from all countries, particularly those that practice bundle packing or pack oriented loose leaf packing from the farmer to the GLT. Countries that deliver farmer cured green tobacco to the GLT, that do not bundle or oriented leaf, will require GLT threshing capacity similar to FIG. 1 and will have lower sieve and filling values, but still can benefit from the invention remaining features and embodiments.

Tobacco leaves coming from the farmers are cured, but not fermented, and normally have relative moisture approximately 18 to 19%.

“Fermented” tobacco is a specific, labor intensive process where the tobacco leaves are manipulated in piles, increasing the temperature and humidity levels, to achieve a distinct character different from green farmer kiln dried tobacco produced normally worldwide. It should be noted that the invention does not normally utilize “fermented” tobacco, but does not restrict the use.

The invention avoids three fundamental steps if compared to a conventional GLT (FIG. 1), which represents important gain in quality and cost reduction: 1) Less total green leaf tobacco is subjected to mechanical threshing. This is achieved by increasing the leaf tipping percentage at the initial blending line, with the resulting increased objectionable stems from the tips removed by an adequate air separator after the lamina cut rag dryer; 2) The tobacco leaves are not first re-dried after threshing; 3) The tobacco leaves are not first pressed/packed after threshing/drying.

Process Steps

The invention utilizes cured green tobacco coming directly from the farmers, with the following steps:

-   -   Leaf grading: grades are made up of the green tobacco from the         farms according to the customer specifications. Production runs         per grade are planned so that the quality of the product is         adherent to the customer specifications;     -   Leaf tipping: leaf tipping involves the cutting of the tip of         the leaf, consisting of variable number of cutters from 2 to 5,         or more, adjustable cutting knives, spaced apart approximately         1″ to 2″ (25 mm-50 mm), depending on the tobacco (“Cutter” or         “Leaf”) and desired leaf fragmentation. The objective here is to         increase leaf tipping percentage at the initial blending table         to approximately 30-35 percent of total weight for both “Filler”         and “Leaf” tobacco; this is a key factor for overall positive         final result of the invention;     -   Leaf conditioning: both tipped and remaining leaf are opened and         softened by means of steam in separate rotary ordering cylinders         for both tipped and non-tipped leaf. Conditioning allows         threshing with minimum breakage. Product temperature is         controlled to ensure no loss in aroma and tobacco taste. Only         the remaining leaf (butts) is subsequently directed to         threshing;     -   Leaf threshing: threshing baskets are used with rotating teeth         moving past stationary rails. The lamina is threshed and removed         from the stem. The incoming leaf is thus changed into lamina and         stem product;     -   Lamina strips separation: classifiers are used to separate the         product from the thresher into lamina and stem. Multiple         threshers and separators can be used in sequence. Total amount         of threshing and separating capacity will be significantly         reduced, by at least 10-20%, compared to conventional process         (FIG. 1), when compared based on the same farmer green tobacco         input weight at the blending table. The lamina strips are         blended with the tips and go to the next industrial process. The         stems can be dried or shredded for later use.

According to the invention, the combined tobacco lamina strips go then through the following steps:

-   -   Additional conditioning and casing process;     -   Bulking Silos;     -   Steam Tunnel (optional);     -   Cutters: laminas enter the cutters at preferably 23 to 24%         relative moisture to generate “cut rag”. However the moisture         may be higher or lower depending on each tobacco blend and/or         cutter capability; no special knives, like serrated         (castellated), are needed for the cutters and the cut width         (C. P. I. or cut per inches) is not limited to a specific range,         however will normally be used in the normal worldwide range for         King Size, Queen Size, Slims, Super Slims, Nano and R. Y. O.; i.         e., 21 to 85 C. P. I. (cuts per inch), or 1.2 to 0.3 mm cut rag         width.     -   Steam Expansion Tunnel (optional);     -   Dryer to reduce the intake relative moisture from 23-24%, down         to 11-14% outtake. However both intake and outtake moisture         percentage may be higher or lower depending on each blend and         dryer capability. Rotary dryer is most appropriate to use in the         invention due to its lower investment cost and superior smoking         quality compared to flash dryers. Although flash dryers, used         alone, will increase filling capacity, use of the invention will         produce overall final cut rag filling capacity above and beyond         what is possible with flash dryer; plus the additional         advantages of lower cost and improved cut rag smoking quality;     -   Air separators for objectionable (OBJ) stem removal from the cut         rag; stem removal of 1 to 3% of original green tobacco weight         would be an average for the invention, however may be higher or         lower. Final cut rag lamina stem content will meet customer         specification;     -   Cooling drum (optional);     -   Shaker separator (optional);     -   Flavor cylinder;     -   Silo for homogenization (optional);     -   Pressing/Packaging.

The naked green stems, resulting from the threshing, can be dried in a drier and pressed/packed similar as in the conventional GLT process (FIG. 1); or, according to the invention, can be reconditioned directly from the green tobacco final threshing (FIG. 3) and then cut and dried in a rotary dryer.

Lamina Performance

Several embodiments are described to support this invention, the first of which relates to leaf lamina performance. The process generates an improved better green strip lamina due to a special tipping setup, consisting preferably in 2 to 5 adjustable cutting knives, spaced approximately 1″ to 2″ (25 to 50 mm), which represents approximately 30-35% in total lamina weight for “Filler” and/or “Leaf”, generating more and larger leaf tip and strips fragments, by-passing the threshing sector. Therefore, only a reduced butt portion is threshed, resulting in better lamina overall total fragmentation.

The limit of the tipping cut will also help determine the quantity and width of threshing stages necessary for a certain throughput; however, up to approximately 20% reduction is possible. As an example, when compared to a conventional GLT (FIG. 1), the third and fourth stages potentially can be eliminated. This should be seen as only an example and does not exclude other possible configuration thru use of the invention and its embodiments.

The special tipping setup can generate the presence of objectionable stem pieces in the cut rag tobacco after the lamina cutter machines, which is detrimental to cigarette quality, resulting in rejection during production particularly on today's high-speed cigarette makers. To minimize this problem, an air separator(s) is introduced after the cut rag dryer (FIG. 3), thus eliminating problems in the formation of the tobacco rod during the cigarette manufacturing process due the excess of objectionable stem, and ensuring high quality cigarette product. Depending on the tobacco blend (Cutter or Leaf) a balance between the maximum stem percentage allowed into the cutters and the stem removal percentage capacity of the separator, will help determine the tipping percentage of total green leaf intake at the blending table in the GLT (FIG. 3).

Stem Performance

Green stem processed and cut as per the invention (FIG. 3), results in improved filling capacity and sieve analysis compared to stem processed in conventional GLT and Primary operations (FIGS. 1 and 2).

The naked green stems, resulting from the threshing, can be dried in an apron drier and pressed/packed for future use in a conventional Primary (FIG. 2) or, according to the invention, can be reconditioned directly from the green tobacco final threshing (FIG. 3) and then cut and dried in a rotary dryer for future add back in the invention or in a conventional Primary.

The invention process avoids intermediate stems drying and pressing/packing. The naked green stems are first cut to be dried in sequence in a Rotary Dryer, giving a higher filling capacity stem as an additional advantage of the invention.

The Quality of the Cut Rag Product

The final cut rag produced as a result of the invention allows today's typical individual King Size cigarette cut rag weights of 725 to 735 mg, to be reduced to levels of 675 to 700 mg when invention produced cut rag is included at a percentage of 20 to 40 percent of total blend; individual cigarette cut rag weights below 675 mg may be obtained by increasing invention produced cut rag lamina and stem to 41-100 percent of the total blend. Each cut rag blend and cigarette maker requires production trials to determine final optimization.

Finally, the product obtained utilizing the invention results in cigarettes with less cut tobacco weight per cigarette, uniform rod firmness with low incidence of loose ends, improved runnability and lower cigarette rejection rates for modern medium and high speed cigarette makers. Also equally important is that the cut rag tobacco produced utilizing the invention maintains original farmer cured green tobacco taste and aroma at levels at least equal to conventional GLT and Primary processes.

Use of the Equipment

With the invention process, it is possible to reduce the conventional threshing lines capacities by up to two stages of the threshing line, or approximately 20% of a conventional GLT (FIG. 1), which is a significant economic advantage; reducing equipment, floor space and energy consumption.

The method does not require a conventional 5-stage line, but allows the utilization of existing GLT and Primary equipment which can be rearranged with the elimination and/or substitution of steps and equipment in order to achieve the results of the invention process.

If a company already has a conventional GLT, it can be used to convey lamina strips from whatever stage separator (ideally after the 1st and 2nd stages) of the GLT directly to the casing cylinder of the Primary, when GLT and Primary are in the same site; or packed in cases when need to be transported to the Primary elsewhere or need to be blended with other grades at the Primary. This modality, however, must be in balance with this process and all its relevant embodiments.

This embodiment describes an alternative feature of the invention. The conversion or adaptation of a GLT or Primary processing lines, or any feature derived therefrom to achieve the results of the invention is part of this Patent.

Flexibility for the Use of Different Equipments

The invention does not require specific types of equipment for threshing nor drying. The invention process can use vertical thresher/separator (VT), conventional horizontal thresher, Counterflow separator (CF), Multisep (MS), or a combination for threshing; and rotary dryer or flash dryer for drying lamina, and/or apron dryer or rotary dryer for stem, depending on end use. Even hand stripped tobacco can be used instead of mechanical threshing, followed by the subsequent steps outlined in the Patent.

The invention process allows existing and/or used equipment along with possible certain new equipment to be relocated and repositioned in order to achieve invention process results.

FIG. 3, therefore, allows for an interpretation of this process, and FIGS. 1 and 2, referring to the conventional GLT and Primary configurations, are shown to highlight the differences with the invention.

Environmental Sustainability

The theme of carbon credits or exchange in the carbon market is covered in the production concept of the invention, as it will reduce greenhouse gas emissions and, consequently, increase the amount of emissions available for sale, if it is below the limit, or will reduce the quantity of emission to buy if it is above the limit. This is only applicable in countries where it is legally required or possible.

The invention motivates changes in the economic production of cut tobacco for cigarettes by the effective reduction of electric power and fuel for steam generation due to elimination of double drying process, double pressing process and less threshing/separators and transports between stages.

The invention is adherent to the Sustainable Development Goals (SDG 9: “Industrial innovation and infrastructure” and SDG 12: “Responsible consumption and production”), also known as the Global Goals, adopted by all United Nations Member States in 2015 as an universal call to action to protect the planet by 2030, with special focus on environmental sustainability.

Energy Savings

Considering the elimination of two industrial apron dryers for lamina and stem, we get an economy of steam and consequently of boiler fuel, whether of hydrocarbon, firewood, coal, electricity or other origin. To quantify the energy gain with elimination of the lamina and stem dryers at a conventional GLT, the following criteria can be used:

-   -   Lamina dryer: for each kg of lamina, an average of 0.30 kg of         steam is necessary in the drying section and more 0.15 kg of         steam in the re-ordering section.     -   Stem dryer: for each kg of stem, an average of 0.35 kg of steam         is necessary for drying.

Therefore, the economy for a 10,000 kg tobacco line (8,000 kg lamina and 2,000 kg stem) will be 3,600 kg/h of steam for the lamina dryer and 700 kg/h of steam for the stem dryer in a total of 4,300 kg/h steam which represents an economy of approximately 2.9 cubic meters/h with wood logs (40% moisture/75% energy efficiency), or 290.6 kg/h of BPF oil (90% of energy efficiency). Considering that a conventional 10 ton/h GLT requires an average of 6,000 to 7,000 Kg/h of steam, the 4,300 Kg/h due the elimination of both lamina and stem apron dryers, correspond to 70 to 60% less steam with the invention.

Considering 1 shift of 8 hours, 22 days per month:

-   -   Wood economy: 2.9 cubic meters×8 hours×22 days=510.4 cubic         meters/month.     -   BPF oil economy: 290.6 Kg/h×8 hours×22 days=51,145.6 Kg/month.

Regarding carbon credits, the absorption of carbon dioxide from the atmosphere by the growth of trees is made from the determination of the potential carbon stock of the species of tree and generates carbon credits due to the sequestration of greenhouse gases. According to Silva (1996) et al in the Embrapa publication (ISSN 1980-3958, August, 2011), the formula for estimating carbon stocks by reducing Eucalyptus biomass used for steam generation is: Content of C=(wood logs volume+25%)×(basic density 0.49)×(carbon content 0.42).

Considering that the reduction of wood consumption due the invention is 2.9 m³/h with wood logs or 510.4 cubic meters/month, the content of C=(510.4+127.6)×0.49×0.42=131.3 carbon stock/month operating in 1 shift, 8 hours/day, 22 days/month.

The invention removes several conventionally used steps that allow a significant reduction in equipment and energy savings:

-   -   01 apron dryer for laminas;     -   01 apron dryer for stems;     -   01 set of hydraulic press;     -   all 3rd threshing stage;     -   all 4th threshing stage;     -   01 slicer for the pressed dried lamina;     -   01 re-ordering cylinder for the dried stems.

Total Kw eliminated by the steps reduction: approximately 600 Kw, which represent 105,600 Kw/month, considering 1 shift of 8 hours, 22 days. Considering that a conventional threshing line for 8 to 10 ton/h capacity has an average of 1,500 Kw of electric energy consumption, this reduction represents an average of 40% less energy.

In the conventional process the tobacco leaves come from the farmers at about 18/19% (relative moisture) and in the final step of the process dry to 12.5% for packing. Consequently, is necessary to re-order from 12.5% back again to 23/24% for cutting, and then again reduce to 11-14%; for final cut blend; whereas in the invention process, the moisture gradient from green tobacco to cut tobacco is only from green tobacco (18/19%), to threshed and tipped lamina at the cutter (23/26%) to final cut tobacco (11/14%). This represents a reduction in steam requirement of 10% to 20%.

The direct connection between GLT and Primary (FIG. 3), on the same site, generates a significant reduction in logistics, eliminating intermediate transports by forklifts or trucks with gains in efficiency with reduced fuel consumption and pollution.

The tipping setting together with the stem separation in the Primary, instead of in the GLT, allows only three stages compared with the conventional 5 stages lines for equivalent throughput, with an additional important energy savings. The invention uses horizontal multi-separators in the 1st and 2nd stages and a vertical separator as the 3rd and final stage. However, this 3rd stage could also be horizontal. The invention does not require specific types of equipment for threshing, and is able to use a vertical thresher/separator (VT), horizontal thresher, “Counterflow” (CF) type separators, Multi-separators (MS), or even hand stripping, or combinations. The basic difference is 3 stages versus 5 conventional ones and maintaining the same production by cutting tips increased with the removal of the stems from the tips in the Primary process.

Process Application Flexibility for Global Cigarette Manufacturers

The invention produced cut rag can be utilized not only as add-back in a conventional Primary process to be added to other blend components, but also dried and packed according to the invention concept (FIG. 3) or as a final blend with addition of other components (scraps, stems, recon, oriental) to be transferred to an on-site packing or Secondary facility for cigarettes, R. Y. O. (Roll Your Own), et al production.

Optionally, it can be fed directly to a cigarette maker in the Secondary (FIG. 3), with previous adequate tobacco beetle elimination treatment.

This embodiment represents also the worldwide flexibility for integration of Primary and Secondary operations. The invention allows, among also others, the following options for cigarette making operations:

-   -   Existing conventional Primaries (FIG. 2) with the installation         of adequate add-back lines, can increase existing Primary         capacity by 10 up to 100 percent by use of invention cut rag         produced elsewhere from anywhere in the world, with increased         filling capacity, improved sieve analysis and lower cost. This         alternative may require specific additional investments such as         increased silo, press, etc., capacity to properly balance the         overall Primary potential.     -   New satellite primaries worldwide can operate anywhere without         leaf lamina inventory, blending line, slicer, conditioning,         blending silos, steam tunnels, leaf and stem cutters, stem and         leaf dryers, coolers, etc. This can be done establishing         Primaries capable of manufacturing diverse blends with just         add-back lines, shakers, flavor light conditioning cylinders,         small dryer and blending silos. From the silos, final cigarette         blends can be transported directly to cigarette makers, or         packed for future use.

Process Efficiency

The invention process eliminates the duplication of the pressing and packaging steps as per conventional GLT and conventional Primary (FIGS. 1 and 2).

Regarding threshing capacity, the invention concept is more compact and economic than a conventional 5 stages threshing line. Total installed threshing capacity of the invention process compared to conventional GLT lines, can be approximately 20 percent less.

The invention tipping cut, which represents 30-35% in total lamina weight for Flue Cured “Filler” and/or for Flue Cured “Leaf”, result in a better lamina fragmentation. This concept allows a better lamina fragmentation even with only 2 or 3 threshing stages in comparison with the 5 stages lines.

The process generates more stem percentage processed thru the lamina cutter, compared to conventional Primary, which need to be removed by the utilization of an adequate stem separator, after the cut rag dryer.

The invention does not need the expensive apron driers used in the conventional GLT's for lamina strips. It also does not need the presses with high chargers and piston stroke necessary to handle the volume of the lamina strips after the apron dryer, common in conventional GLT.

If the cut rag from the final blending silo (FIG. 3) is fed directly to the cigarettes makers in the Secondary, one pressing/packing step is also eliminated. This alternative also requires adequate tobacco beetle control.

It is important to note that the figures and descriptions do not have the ability to limit the forms in which this invention may be executed, but rather to illustrate and make the conceptual innovations revealed in this solution understandable. Thus, the descriptions and images must be interpreted in an illustrative and non-limiting manner, and there may be other equivalent or similar ways of implementing this invention concept that do not escape the protection spectrum outlined in the proposed solution. 

1-12. (canceled)
 13. A method for processing green leaf tobacco into cut tobacco comprising: a) grading/blending the green leaf tobacco; b) tipping the augmented green leaf tobacco; c) conditioning butts and tips of the green leaf tobacco; d) picking butts and tips of the green leaf tobacco; e) threshing the lamina leaf (butts) of the green leaf tobacco; f) separating the lamina/stem; g) conditioning and casing the lamina; h) blending and bulking lamina; i) cutting the lamina to generate cut rag; j) drying the lamina cut rag; k) removing of objectionable stems (OBJ); I) passing through a flavor cylinder; and m) pressing/packaging.
 14. The process according to claim 13, wherein step a) the green tobacco leaves are cured and not fermented, and baled with a relative humidity ranging from 18% to 19%.
 15. The process according to claim 13, wherein step b) has at least two adjustable circular knives, spaced approximately from 1″ to 2″ apart, varying the number of knives, and cut size according to the type of tobacco.
 16. The process according to claim 13, wherein steps e) and f) has only threestages of threshing/separation.
 17. The process according to claim 13, wherein step g) comprises increasing a relative humidity to 23% to 26% for lamina strips.
 18. The process according to claim 13, wherein step g) comprises supplying green tobacco directly to the Primary with 18 to 19% relative humidity.
 19. The process according to claim 13, wherein step j) comprises reducing the relative humidity of the cut tobacco to 11% to 14%.
 20. The process according to claim 13, wherein after step h), optionally, adding steam conditioning occurs before the cutting machine.
 21. The process according to claim 13, wherein step k) comprises providing a vertical airseparator.
 22. The process according to claim 13, wherein after step k), optionally, passing through a cooler.
 23. The process according to claim 13, wherein after step k), optionally, passing through a screening shaker to remove fine particles and dust.
 24. The process according to claim 13, wherein prior to step m), optionally, passing through final silos for homogenization. 